Table of Content

25 February 2010, Volume 21 Issue 04

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Toward Green Manufacturing and Intelligent Manufacturing——Development Road of China Manufacturing

LU Dong-Xiang-

2010, 21(04):  379-386,399. 

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Study on a Vertical Scanning System with Large-stroke and Nanopositioning Resolution

WANG Chu-Zhen, WANG Sheng-Fu, XIE Tie-Bang

2010, 21(04):  387-390,476. 

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The purpose of this study is to develop a vertical scanning system with large-stroke and nanopositioning resolution,in which the coarse positioning was performed by sliding rail, brushless DC motor and precision lead screw,and the fine positioning was performed by parallel board flexure hinge and piezoelectric ceramic.The mechanics analysis and the natural frequency of the parallel board flexure hinge were carried out.

The displacements of the coarse actuator and the fine actuator were measured by the same

laser interference displacement measuring system respectively.The displacement range

of 40mm and positioning resolution of 5nm of the vertical scanning system can be achieved.

Output Displacement Analysis of a Parallel Leaf Spring

YANG Xue-Feng, LI Wei, WANG Yu-Qiao, XIE Guan, SU Xiu-Beng

2010, 21(04):  391-393,436. 

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According to the symmetrical structure,the output displacement characteristics of a parallel leaf spring at large deformation were analyzed by using the Bernoulli-Euler formula and the homotopy analysis method.And a half beam model was established based on the force analysis and deformation analysis of the leaf spring.The guiding displacement and coupled displacement formulas were derived and verified by finite element analysis.Results show that the analytic solution has higher accuracy even when the guiding displacement and the coupled displacement reach to the 34% and 8% of the length of the leaf spring separately.

Structure Comprehensive Optimization for Front Body-in-white of Car

GAO Yun-Kai, SUN Fang, CHENG Jin-Shan, TU Hai-Yan

2010, 21(04):  394-399. 

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In order to improve the performance of vehicle’s passive safety and other performance,engine compartment of a domestic car was optimized.According to the original geometric model,a finite element analysis model was established and the static,modal and 100%RB(rigid barrier) collision analysis were executed.Considering the general arrangement and the joint position of the car,the solid element model was established and the multi-case topology optimization was carried out.Size optimization was implemented for the original design under the integrated case which includes static,modal and equivalent-static 100% RB case.According to the results of topology optimization and size optimization,the FEM was modified and validation was carried out. The results indicate that the performance of 100%RB impact has been improved and the first order bending mode, bending stiffness, torsion stiffness of the front end are increased nearly by 10%, respectively.

Analysis and Test of Fluctuating Friction Torque in High-precision Ball Screw

KANG Xian-Min, FU Wei-Beng, WANG Da-Cheng, LI Ting, WANG Shi-Jun

2010, 21(04):  400-405. 

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A theory to analyse the friction torque on ball screw based on friction acting style of ball rolling into and out of groove was firstly brought forward according to the derivation of friction torque on ball screw based on the Hertz contact theory on the point contact model.Then ball rolling into and out of groove was coincided to be as the main reason of friction torque fluctuating and preload was the key determinant factor.The test results indicate that friction torque is proportional to rotational speed and volatility frequency is consistent with the frequency of ball rolling into and out of groove,which proves the analytical methods and the theory is correct.

Characteristic Analysis of Cross Thrust Force and Pull Force for a Four Degrees of Freedom Working Mechanism System

HAN Jun, CHEN Gao-Jie, ZHANG De-En, XIAO Wei

2010, 21(04):  406-410. 

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Aimed at analyzing the walking ability of excavator,a kinematics model for a four degrees of freedom working mechanism system using Denavit-Hatenberg homogeneous transformed matrix was constructed,and the functional relationship of multi-joint arm working unit related to the basis coordinate system was established.The optimum models of solving the maximum cross thrust force and the maximum tensile force for

the four degrees of freedom working mechanism system were proposed according to the connecting relationship of working mechanism system and the different drive mode.

The sequential quadratic programming(SQP) method was employed to solve the linear programming model.The distribution characteristics of the maximum cross thrust force and the maximum tensile force in the operation space were obtained.

A Micro Resonant Accelerometer

HE Gao-Fa, TANG Yi-Ke, ZHOU Chuan-De, HE Xiao-Beng, TUN Yang

2010, 21(04):  410-414. 

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In order to design and fabricate a micro resonant accelerometer with high sensitivity,based on compliant hinge mechanism and double-ended-tuning-fork(DETF),

the structure of the accelerometer was designed herein.The sensitivity of accelerometer was analyzed via the theoretical method and finite element method (FEM).The parameters of the structure were optimized.The accelerometer was fabricated with micro-electro-mechanical system(MEMS) technology.Based on the principles of detecting,a printed circuit board(PCB) was designed and fabricated.The results of the test show the sensitivity of this accelerometer sample is about 55.03Hz/g,and the resolution is about 182×10^-6g.

Study on the Characteristics of Ultrasonic Elliptical Vibration Turning

WANG Gui-Lin, LI Wen, DUAN Meng-Lan, ZHANG De-Yuan

2010, 21(04):  415-419. 

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Ultrasonic elliptical vibration cutting technology as a new novelty machining technology has a very wide application prospects in the precision & ultra-precision machining.A simple mode for elliptical vibration cutting forces was setup,the kinematical properties of elliptical vibration cutting were analyzed and the formulas related to the cutting duty cycle,the remain height of vibration in cutting direction,the frequency and amplitude of ultrasonic elliptical vibration cutting were deduced.And then from these formulas the work characteristics related to the surface roughness, forming accuracy and the efficiency of machining were given out.The cutting force and surface roughness experiments for ultrasonic elliptical vibration cutting were also conducted to verify these results. 

Hybrid Particle Swarm Optimization Algorithm for Assembly Line Balancing Problem-2

LU Jian-Sha, JIANG Ling-Ling, LI Xiu-Lin

2010, 21(04):  420-424. 

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This paper discussed the types of assembly line balancing problem and related algorithms,presented the mathematical description of assembly line balancing problem-2.Using PSO’s global search capability and high efficient of searching with SA’s local search capability,proposed a hybrid PSO algorithm for assembly line balancing problem-2 and given out a solving procedure based on the analysis of standard PSO algorithm for assembly line balancing problem-2.The result of example shows that the proposed hybrid PSO algorithm is more effective than standard PSO algorithm on assembly line balancing problem-2．

Research on Batch Scheduling Problem in a Flexible Job Shop

TUN Xiu-Li, LI Su-Jian, DU Pan-Hua

2010, 21(04):  424-429. 

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A multi-objective integrated genetic algorithm(MIGA) was proposed to solve both of the assignment of machines to corresponding operations and the scheduling of operations on assigned machines in flexible job scheduling problem at the same time.MIGA used random weights to convert the multi-objective problem to a single-objective problem. An operation-extended coding method was presented.The elitist strategy and the niche technology were integrated into the roulette selection operation to speed up the convergence and to improve the diversity of the population respectively.A new scheduling-batch oriented active decoding method was designed.Finally,some benthmark problems were experimented.The results prove that MIGA can solve mass variety and small batch scheduling problem in the flexible job shop effectively and efficiently. 

Study on Process Planning for Reconfigurable Manufacturing Systems

JIANG Shi-An, HU Gong

2010, 21(04):  430-436. 

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A method of process planning for reconfigurable manufacturing systems was proposed.Firstly,analysis of factors which influencd operation clustering,and coding

rules were used to set values for factors,then mathematic model and algorithm of

clustering for the similar operations were established;subsequently,a evaluation index system was established,and multi-fuzzy comprehensive evaluation was used to evaluate the operation clusters.[JP2]Finally,the results show that the optimal operation clusters are

obtained over the entire part family,and the number and scope of reconfiguration were reduced markedly.

Discovery Method of Virtual Prototyping Based on Function Requirements 

YUAN Yi-Ping, SUN Wen-Lei, SHU Ying

2010, 21(04):  437-442. 

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In design process of virtual prototyping of complex products,it has already become the most urgent problem to be solved that discovery methods of resources cannot integrate with functional model of complex products.An effective and feasible approach to resource discovery based on function requirement semantics was proposed herein.The functional model and the function requirement ontology was first built,which provided an unified manner to describe the function requirements semantically.Furthermore,virtual prototyping model ontology were defined,and the method of resource discovery based on function requirement semantics was designed.Finally,the system implementation architecture was built up.

Welding Robot Path Optimization and Simulation for Body in White

CHAO Yong-Sheng, LIU Hai-Jiang

2010, 21(04):  442-445. 

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To balance the workload of multiple welding robots,an approach of combining genetic algorithm and simulation analysis was proposed.Based on the analyses

 of welding point sequences,priorities of welding points were defined.Welding points were allocated to multiply robots and the objective was to minimize the welding time of station.

Adaptive genetic algorithm was applied to seek the optimization solution.The three dimensional model of welding production line was built in eM-power software.The welding robot simulated the allocated welding points, which settled the collision between two robots or between robot and parts, and free collision path was selected finally. Welding path simulation can shorten the planning time sharply in virtual environment.

FEM Study of Effect of Flip Chip Packaging on MEMS Performance

WEI Song-Qing, TANG Ji-Ying, SONG Jing

2010, 21(04):  446-451. 

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Flip chip packages with area array patterns of 2×2,4×4,6×6,8×8 bumps were investigated using finite element method.The stress distribution and warpage of the flip chip were simulated with respect to different bump patterns.The stress and warpage can lead to a maximum relative change of 5% in the pull-in voltage of a microcantilever and 110% in the first natural frequency of a microbridge after flip chip packaging.

Tool Orientation Control Method Based on Divided-area Algorithm

LI Bing-Lin, WANG Hua-Lin, HU Xu-Jin, LI Cheng-Gang

2010, 21(04):  452-457. 

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This paper presented a methodology and algorithm of tool orientation control for 5-axis sculptured surface CNC machining. First, the surface triangle grids were generated, and the normal vectors of the surface triangle patches were compared, then the patches the normal vectors of which were within a given tolerance were combined as a area.A divided-area algorithm was proposed to find the initial tool orientation by configurating a cone mean vector of the unit vector set,initial tool orientation was optimized and corrected.Finally,computer implementation and examples were provided,the developed method can be used to automate the planning of tool orientation generation.

Processing Method for End Effects of Local Mean Decomposition Based on Self-adaptive Waveform Matching Extending

ZHANG Gang, CHENG Jun-Ku, YANG Yu

2010, 21(04):  457-462. 

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The LMD is a new method for analyzing non-stationary signals. It can decompose complicated signals into a set of single-component signals,each of which has physical sense. But performing the LMD will produce end effects which make results distortion. After analyzing the reasons for these,a self-adaptive waveform matching extending method was proposed to overcome the end effects of LMD. Considering both signal’s inner discipline and the edge of the signal,therefore the extension was reasonable and possessed adaptability.The analytical results from simulated signals and actual engineering signals demonstrate that the new method can be used to solve the end effects effectively.

Analysis of Resist’s Flow Behavior during Micro Imprinting

WEN Ju-Yang, WEI Zheng-Yang, XIONG Xiao-Dong, DU Jun, LEI Bing-Heng

2010, 21(04):  463-469. 

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Aiming at analyzing the flow behavior of low-viscosity resist used for room-temperature micro imprinting and its impact on the fidelity of pattern transfer,CFD(computational fluid dynamics) finite element simulation was conducted.Variations in tool geometry,resist thickness and micro imprinting working condition affected resist filling modes greatly.Finally,single-dual peak transfer curves and filling efficiency curves were plotted.The resist’s flow behavior was analyzed from both theory and experiments.The research here seeks to investigate the resist’s flow behavior and provides theoretical basis for optimizing fidelity of pattern transfer.

Least Parametrical Modification Method of Spiral Bevel Gear Tooth Surface Errors

CAO Kang, TANG Jin-Yuan, LI Guo-Shun, LIU Yan-Ping

2010, 21(04):  469-476. 

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The sensitivity relationship between the machine adjustment parameter errors and surface errors of the hypoid gears was researched herein,and the major impact of the machine adjustment parameter errors were determined based on the method of SFT(spiral format title),and a least parametrical modification method of tooth surface errors was proposed.The tooth surface mathematical model of a spiral bevel gear by SFT was established,and the equations of theoretical tooth bearing and error tooth were established,the analytical expression of tooth surface processing errors caused by the machine adjustment parameter errors was derived,and the concept of error influence coefficient

was proposed,and the impact of surface errors caused by machine adjustment parameter errors can be obtained according to the error influence coefficient.Through comparison

of theoretical tooth bearing and error tooth,the effect law of tooth surface node processing errors and the whole tooth surface normal errors were determined.The major impacts of the machine adjustment parameter errors were determined by analytical and numerical method.The relationship

between the machine adjustment parameter errors and surface errors was determined by the functional method,and the optimal solution of the machine adjustment parameter was solved by using the sequential quadratic programming method.The correct method

proposed can effectively reduce the tooth surface error by means of experimental verification.

System Modeling and Control for Switching Power Amplifier of Magnetic Bearings

WANG Jun, XU Long-Xiang

2010, 21(04):  477-481. 

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Switching power amplifier of magnetic bearing was a nonlinear system.The performance of the switching power amplifier affected the stability of the magnetic bearing control system.A way of establishing the closed-loop system model of magnetic bearing was presented.Based on the analysis of three-level power amplifier principle, the nonlinear circuit model was replaced by using Fourier series and the transfer function of the nonlinear net was established.A closed-loop system math model of three-level power amplifier was obtained.The model was verified by MATLAB simulations and experiments.The results show that the deduced system model can effectively reflect the actual characteristics of control system for three-level power amplifier and the proposed model is feasible and effective.

Statistical Analysis of Short Crack Density Field at Meso-scale Level

AO Bei, ZHANG Ding-Hua, WU Guan-Hua

2010, 21(04):  482-486. 

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Circular sectional specimens were designed by the characteristics of Micro-CT,and a LY12 alloy specimen containing fatigue crack was acquired through fatigue test under displacement control.The specimen was scanned and reconstructed by means of Micro-CT,images of density field were obtained,and the 3D crack morphology was extracted. Experimental results reveal that there exist uneven,rough crack surface within the specimen.Statistical analysis of density field was quantified at meso-scale level,including interior,adjacent region,path of propagation of the crack and towards both sides of crack.The statistical results show that densities of region of crack,adjacent region are lower than normal region,and the damage of fatigue is uneven.

Dual DSPs Parallel Controlling Ultra-aduio Frequency Pulsed TIG Welding Machine and Its Applicability

HUANG Song-Chao, JI Bo-Jin, HU Hai-Ying, JIAO Xiang-Dong

2010, 21(04):  486-490. 

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Based on two sets of bridge model inverter DC main circuit parallel modulation mode,a high power ultra-audio frequency DC pulsed TIG welding machine was developed successfully by using dual DSPs parallel processing digital controlling way.The transition rate of the pulsed current in rising and falling edge of the welding machine is more than 50A/μs,and the pulsed frequency can reach to 30kHz and above.Applicability experimentations indicate that the ultra-audio frequency DC pulsed arc generated by the TIG welding machine is provided with arc-ultrasound effectiveness and with arc high frequency effect.The welding machine has a direct influence on enhancing the quality and performance of the welding joint.

A Vehicle Performance Self Learning Method Applied to Robot Driver

CHEN Gang, ZHANG Wei-Gong, GONG Zong-Xiang, SUN Wei

2010, 21(04):  491-495. 

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To reduce the preparation time before vehicle test,a vehicle performance

self learning method applied to robot driver was proposed.The vehicle geometric parameters and vehicle performance parameters which influence the driving behavior of robot driver were self learned. The vehicle geometric parameters were learned by key box, and the command signals applied to the accelerator and brake actuators were determined by the power needed to drive the vehicle during the process of vehicle performance parameter self learning. Furthermore, the capability of control parameter self-optimization on line made it possible to compensate for the wear of vehicle during the long term test. Experimental results demonstrate that the self-learning, self-adaptation and self-compensation are realized by the proposed method and the robot driver can be applicable to a wide variety of vehicles. Moreover, the accuracy of vehicle speed tracking meets the requirements of vehicle test. Therefore, the method provides a solution to eliminate the uncertainty of vehicle test results by human drivers.

 Research on Application of Multidisciplinary Design Optimization to TWB Door Lightweight

HU Chao-Hui, CHENG Ai-Guo, WANG Guo-Chun, ZHONG Zhi-Hua

2010, 21(04):  495-499. 

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Sampling points were obtained by using uniform Latin squares design of experimental method, and the multidisciplinary design optimization(MDO) approximated system,including the door stiffness, strength and side crashworthiness,was constructed by the moving least-squares response surface approximate method.The approximate model was then optimized by using sequential quadratic programming method. The performance of the door system,including the vertical stiffness, strength and side crashworthiness,

was improved by optimizing the positions of the welding line as well as thickness of each part. In addition, the weight of the door is also reduced.

Static Analysis and Improvement on Clutch Driven Plate Assembly

WANG Jing-Chun, FAN Zi-Jie, HOU Yong

2010, 21(04):  500-503. 

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The stiffness and strength of clutch driven plate assembly were experimentally and numerically studied,an improvement design on the stress concentration was given.First,a finite element model of clutch driven plate assembly was built,the stiffness and stress distribution were calculated;then the corresponding tests were performed,and the FE model was verified;finally,the improved design was given according to the FE calculation.The improved design can reduce the stress concentration and the structural mass.